Quality assurance for PROFIsafe products and systems

This article from Profibus & Profinet International outlines the quality-related issues surrounding PROFIsafe.

One of the most important steps in the technology development of PI (Profibus & Profinet International) is the completion of PROFIsafe, the specification for functional safe communications for Profibus. This step is described as a quantum leap in the world of safety-oriented automation and opens up a broad range of new possibilities. Since 2005, the PROFIsafe profile has also been available for use in Profinet IO systems. The relevant approvals from TÜV and BGIA (the German Institute for Occupational Safety and Health) were awarded immediately on conclusion of the technology development.

PROFIsafe has since become an international standard IEC 61784-3-3. Steps are also currently being taken to establish PROFIsafe as a national standard in China.

Since its first publication, PI says PROFIsafe has become the world's leading and most consistent technology for functional safe communications. By the end of 2007, more than 41,000 plants were in operation with a total of more than 410,000 PROFIsafe nodes - of which approximately 10 per cent are in process automation plants.

The quality of products and systems is crucial, particularly in areas of safety. And in order to guarantee these for PROFIsafe, PI has initiated a range of structural and organisational measures. These include documents, such as the 'PROFIsafe Policy' and 'Environmental Guideline,' the introduction of certification for PROFIsafe products, the setting up of PROFIsafe Competence Centres, and training courses with a final exam for qualification as a Certified PROFIsafe Engineer.

PROFIsafe offers a uniform profile for safety applications on the basis of Profibus DP and Profinet IO networks. It is used in exclusively Profibus DP (V1 mode) or Profinet IO networks (V2 mode), but is also suitable for cross-system use in mixed networks (V2 mode) with both Profibus DP and Profinet IO. PROFIsafe has also since been approved for wireless transmission technologies, such as WLAN and Bluetooth. When incorporated with data security technology, it can be used over Ethernet backbones.

Already PROFIsafe is being used for safe communications in both manufacturing and process automation, offering the following advantages: reduced cabling, flexibility during commissioning, expansion and/or revamp, consistent engineering, and diagnostics.

Standards compliance

PROFIsafe defines how fail-safe devices communicate with safety controls over a network so reliably that they can be deployed in safety applications up to SIL3 according IEC 61508 or PLe/Category 4 according ISO 13849-1:2006 (which succeeds EN 954-1). To achieve this safe communication, it uses a profile, ie a special format of the user data and a special protocol. The spectrum of devices ranges from safe remote I/O modules to emergency stop pushbuttons, light curtains, laser scanners, overfill safety systems, transmitters for drives with integrated safety functions, and robots.

The PROFIsafe profile uses the black channel principle, which specifies that the safety layer is independent of the underlying transmission path, ie it includes the Profinet/Profibus transmission and the backplane buses of PLC and field devices.

PROFIsafe can be easily implemented over software and, used in conjunction with Profibus and Profinet, covers the whole spectrum of safety applications in process and manufacturing automation. If the software of Profibus DP devices is upgraded to V2 mode, the Profibus DP interface only needs to be replaced by a Profinet IO interface to enable operation directly on Profinet IO networks.

In the world of automation, functional safety is crucial and must be exceptionally reliable, as it controls the protection of man, machine and environment. It is therefore essential to ensure consistent public relations and the careful implementation and use of PROFIsafe technology. In order to ensure this is the case, PI has defined special measures.

PROFIsafe Policy

The PROFIsafe Policy document provides a set of rules for companies that want to provide PROFIsafe products and systems. It describes the necessary development steps for PROFIsafe products, including the necessary QA measures, regulates the use of the PROFIsafe logo and provides a summary of the relevant standards and documents. This document has been drawn up in collaboration with TÜV and BGIA and is included by said organisations in the approval process for the PROFIsafe technology. All participating companies and institutions are obliged to comply with the rules of the PROFIsafe Policy.

The IEC 61508 standard defines special requirements, such as increased electromagnetic immunity, without detailing specifics. This gap is filled by a supplementary guideline, PROFIsafe Environment, which promotes the development and use of fail-safe devices and fail-safe hosts.

There are two ways to implement the PROFIsafe driver software in devices: in accordance with specifications or by using a starter kit that is available on the market. The advantages of a starter kit are obvious: tested and pre-certified driver software, additional valuable information, tools and technical support. All available ASICs and communication layers can be used for the interfaces to Profibus and Profinet. The PROFIsafe driver software just needs to be adapted accordingly.

Product certification

Conformity of PROFIsafe products (devices and hosts) to the PROFIsafe protocol must be tested in accredited PI test laboratories and certified by the PI certification office. The condition for the use of such products in safety applications is a safety certificate from one of the renowned testing agencies, such as TÜV or BGIA, according to IEC 61508. In turn, this certificate can only be obtained if the product has been awarded a PROFIsafe certificate by the PI certification office. A PROFIsafe certificate is granted on the basis of a positive test report, which is issued by an accredited PI test laboratory (PITL). The PROFIsafe Test Specification defines the roles and tasks of the assessment bodies (eg TÜV, PNO) and the PITLs. The tests are designed to ensure conformity of the Profibus/Profinet communication functions to the specifications and adherence to the PROFIsafe profile.

The use of certified products reduces costs for end users. The certification test is crucial to quality assurance. The aim of device certification is to ensure the necessary safety for users when interconnecting devices from different manufacturers. Implementation of successfully tested devices guarantees fault-free communications with regard to the communication protocol. This enables significant cost reductions when commissioning and replacing devices.

PI has now set up more than 35 Competence Centres (PICC) worldwide. The PICCs offer a whole range of services. These can include seminars on a range of topics, acceptance of development tasks, advice on the implementation of technologies or the commissioning or troubleshooting of plants. Due to the broad scope and the range of application options of these technologies, these services have been broken down into different areas of technical expertise.

The accreditation by PICCs, which covers the scope of PROFIsafe, contains additional conditions due to the importance of functional safety. Because the focus here is on the safety of man, machine and environment, these additional conditions are based on compliance with pertinent legal and technical regulations.

In order to ensure adherence to the required quality, the experts responsible for functional safety at the PICCs for PROFIsafe are also obliged to participate in a workshop that culminates in a final exam. The workshop is run as a collaboration between PI and the TÜV. This workshop must be repeated, and the exam passed, every two years.

Approved training

PI Training Centres (PITC) have been set up in order to ensure a globally uniform training standard for engineers and technicians. The accreditation of the PITC and their experts ensures the quality of this training and thus the engineering and setup services for Profibus and Profinet.

The required high quality of PROFIsafe products and systems depends largely on the quality of the expertise and the applied methods/procedures of the development team. This can be kept at the required level through the implementation of an appropriate training programme. For this purpose, the responsible working group of the PNO, in collaboration with TÜV, have worked out a programme that is offered to interested member companies for personnel training. The two-day training course finishes with a final exam. On successful completion of the course, the experts receive a TÜV certificate as a Certified PROFIsafe Designer. The two-day training course must be repeated every two years. This is designed to ensure that the knowledge of the experts is kept up-to-date.

The Profibus Group

Suite 183
19 Lever Street
Manchester
M1 1AN
UNITED KINGDOM

+44 (0)208 144 9597

uk@profibus.com

www.profibusgroup.com

More from The Profibus Group

New video: cables in PROFINET networks

Posted 1 week ago

PROFINET Webinar December 16th 1800

Posted 1 month ago

Additional measures for PROFINET security

Posted 2 months ago

omlox initiative wins Hanover Fair 2020 Award

Posted 4 months ago

New Profibus competency centre confirmed

Posted 4 months ago

New Video: PROFIBUS vs. PROFINET comparison

Posted 5 months ago

Free webinar: Lightning Surge Protection on Profibus Networks

Posted 7 months ago

Free webinar: Profibus to Profinet gateways

Posted 7 months ago

Online conference and exhibition explores IoT and Industry 4.0

Posted 7 months ago

APL used successfully in test setup at BASF

Posted 7 months ago

OPC UA-PN Companion Specification Version 1.0 announced

Posted 7 months ago

Profinet and IO-Link node count still rising

Posted 8 months ago

PIUK announces more Profinet and Profibus webinars

Posted 8 months ago

New date for Profinet, Profibus and IO-Link Birmingham seminar

Posted 8 months ago

PI UK webinar explores EMC for industrial automation systems

Posted 8 months ago

New date for Profinet, Profibus and IO-Link Scotland seminar

Posted 8 months ago

Automation and Robotics Online Conference scheduled for 2 June

Posted 8 months ago

Profinet, Profibus and IO-Link Birmingham seminar postponed

Posted 8 months ago

Belfast Profinet, Profibus and IO-Link seminar rescheduled

Posted 9 months ago

PI UK events and precautions for Covid-19

Posted 10 months ago

Profinet and OPC UA used by Audi for predictive maintenance

Posted 10 months ago

Profinet, Profibus and IO-Link - Scotland seminar

Posted 10 months ago

IODDfinder automates IO-Link description files

Posted 11 months ago

Profinet protocol gains further security measures

Posted 11 months ago

Progress on Profinet-over-TSN specification

Posted 1 year ago

OPC UA Safety: technical work now finished

Posted 1 year ago

Free seminar: Practical aspects of Profinet, Profibus, IO-Link

Posted 1 year ago

New book: Profinet in Practice

Posted 1 year ago

PI UK to participate in Smart Industry Conference 2019

Posted 1 year ago

PI UK to participate in Connected Manufacturing 2019

Posted 1 year ago

Specification of Profinet with TSN is now complete

Posted 1 year ago

Profinet, Profibus and IO-Link seminar review

Posted 1 year ago

Table-top exhibition at Profibus, Profinet and IO-Link seminar

Posted 1 year ago

Profinet and Profibus node count tops 87 million in 2018

Posted 1 year ago

Agenda published for Profinet, Profibus and IO-Link seminar

Posted 1 year ago

Free seminar: Practical Aspects of Profinet, Profibus, IO-Link

Posted 1 year ago

Cyber security: secure architecture challenges for real business

Posted 1 year ago

Safety & Security - not so different from one another

Posted 1 year ago

UK's PICC to present Professional Design and Practice projects

Posted 1 year ago

PI UK to support The Smart Industry series of Conferences

Posted 1 year ago

IO-Link as the key to implementing Industry 4.0

Posted 2 years ago

Implementing Industry 4.0 using Profinet and OPC UA

Posted 2 years ago

Live demo shows how easily TSN can be integrated in Profinet

Posted 2 years ago

The smart way to Industry 4.0 with Profinet-based technologies

Posted 2 years ago

PI to present Industry 4.0 Demonstrator at SPS IPC Drives 2018

Posted 2 years ago

Free-to-attend PROFIBUS, PROFINET and IO-Link seminar

Posted 2 years ago

Agenda announced for Profibus, Profinet and IO-Link seminar

Posted 2 years ago

New PROFIdrive profile tester and Encoder profile

Posted 2 years ago

Understanding and Applying Profibus, Profinet and IO-Link

Posted 2 years ago

Update on an advanced physical layer for industrial Ethernet

Posted 2 years ago

Learning how to use IO-Link Wireless

Posted 2 years ago

PA Profile V4.0 enables use of Profinet in process automation

Posted 2 years ago

Profinet exhibits first integration of TSN

Posted 2 years ago

Continued growth in Profibus, Profinet, PROFIsafe and IO-Link

Posted 2 years ago

Development of functionally safe communication between machines

Posted 2 years ago

IO-Link Wireless specification completed

Posted 2 years ago

PI UK to present and exhibit at Connected Manufacturing 2018

Posted 2 years ago

Free-to-attend Profibus, Profinet and IO-Link seminar

Posted 2 years ago

Updated agenda: PROFIBUS, PROFINET and IO-Link Glasgow seminar

Posted 2 years ago

Profibus, Profinet and IO-Link seminar comes to Glasgow

Posted 2 years ago

Watch new video on PROFINET and Time Sensitive Networking

Posted 3 years ago

Update on an advanced physical layer for industrial Ethernet

Posted 3 years ago

PI UK to support Connected Manufacturing at Advanced Engineering

Posted 3 years ago

PROFINET test system - quality is the goal

Posted 3 years ago

IO-Link Safety specification ready for implementation

Posted 3 years ago

PI releases new PA Profile - now also available for PROFINET

Posted 3 years ago

PI releases PROFIBUS, PROFINET and IO-Link node count numbers

Posted 3 years ago

Free training on PROFIBUS, PROFINET, IO-Link and IIoT

Posted 3 years ago

Symposium on the topic of Ethernet in process automation

Posted 4 years ago

FDI (Field Device Integration) technology: now ready to use!

Posted 4 years ago

Certified training in PROFINET and OPC UA

Posted 4 years ago

IO-Link's success in the field continues unabated...

Posted 4 years ago

Free Profinet technology workshop for developers

Posted 4 years ago

Profibus and Profinet in process training seminar

Posted 4 years ago

Free-to-attend Process Networking Seminar - Manchester, June 29

Posted 4 years ago

Ensuring drive and motion control applications interoperability

Posted 4 years ago

PROFIsafe: national safety standard for industry in China

Posted 4 years ago

Practical aspects of PROFIBUS, PROFINET, IO-Link: free seminar

Posted 4 years ago

Merging Profibus PA and Profinet: a future-proof building block

Posted 5 years ago

New white paper: Profinet as a platform for process automation

Posted 5 years ago

PI technologies enable innovation for Industry 4.0

Posted 5 years ago

Higher performance for the process industry with PROFINET

Posted 5 years ago

The Profibus and Profinet User Conference, June 2015

Posted 5 years ago

PROFIBUS & PROFINET International announces market results

Posted 5 years ago

Securing automation systems: a step-by-step approach

Posted 6 years ago

Strong growth for PROFINET and PROFIsafe

Posted 6 years ago

Free seminars: digital communications in automation

Posted 6 years ago

PROFINEWS now available on mobile devices

Posted 6 years ago

Free tickets to Profibus Group's 20th Anniversary Conference

Posted 7 years ago

PROFINET helps GE make appliance manufacturing leaner

Posted 7 years ago

Multi-vendor workshops to be hosted at Profibus Conference

Posted 7 years ago

Profibus conference programme to address key industry issues

Posted 7 years ago

PROFINET - A strong driver

Posted 8 years ago

Faster cycle time for PROFINET

Posted 8 years ago

Profisafe celebrates ten years of safety on a common cable

Posted 8 years ago

An introduction to PROFIenergy, an update and a White Paper

Posted 10 years ago

Attend the Profibus & Profinet User Conference for £50

Posted 10 years ago

Profinet, Profibus and Profisafe performance in 2009

Posted 10 years ago

Profibus and Profinet training courses for 2010

Posted 10 years ago

User Conference: Profibus, Profinet, ProfiEnergy and ProfiSafe

Posted 10 years ago

See Profibus and AS-i equipment networked in real time

Posted 11 years ago

Beginners' guide to Profibus and Profinet

Posted 11 years ago

See the latest developments in Profibus and Profinet

Posted 11 years ago

Fieldbus market research to be presented at conference

Posted 11 years ago

Find out about fieldbus systems at user conference

Posted 11 years ago

New book provides an introduction to Profibus

Posted 11 years ago

2009 Profibus and Profinet User Conference

Posted 11 years ago

Wireless Profibus and Profinet for factory automation

Posted 11 years ago

Substantial growth in number of installed Profibus nodes

Posted 11 years ago

Software distributes device descriptions based on EDDL

Posted 11 years ago

Profinet to support energy-efficient production

Posted 11 years ago

Free entry to Profibus and Profinet User Conference

Posted 11 years ago

New version of PROFIsafe starter kit

Posted 12 years ago

2009 Profibus and Profinet conference - Excellence in Automation

Posted 12 years ago

Training course: networked automation and control systems

Posted 12 years ago

FDI team develops draft architecture concept

Posted 12 years ago

Call for papers for 2009 Profibus/Profinet conference

Posted 12 years ago

Over 25million Profibus nodes installed worldwide

Posted 12 years ago

Profibus Group reports on successful user conference 2008

Posted 12 years ago

An introduction to IO-Link for sensors and actuators

Posted 12 years ago

Learn about Profibus DP and PA system design and layout

Posted 12 years ago

Profibus and Profinet User Conference 2008

Posted 12 years ago

First Profinet training course successfully completed

Posted 12 years ago

AS-i training course includes integration with other networks

Posted 12 years ago

Learn about the latest in Profibus, Profinet and Profisafe

Posted 12 years ago

I/O-Link integration in Profibus and Profinet

Posted 12 years ago

Profibus claims global lead in fieldbus market

Posted 12 years ago

PROFIenergy at the Profibus and Profinet User Conference

Posted 12 years ago

An opportunity for hands-on experience with Profibus/Profinet

Posted 12 years ago

Profibus and Profinet User Conference, 29-30 June 2010

Posted 12 years ago

Certified Profinet Engineer course offered in the UK

Posted 12 years ago

A guide to Profibus and Profinet industrial fieldbus networks

Posted 12 years ago

Profibus User Conference 2008 - schedule published

Posted 12 years ago

IEC 61800-7 standard defines PROFIdrive profile

Posted 12 years ago

Profinet offers greater potential for industrial automation

Posted 13 years ago

Draft specification for integration of Hart into Profinet

Posted 13 years ago

Profibus Group reports on successful user conference 2007

Posted 13 years ago

PROFIBUS projects at User Group conference

Posted 13 years ago

A chance for hands-on training in Profibus and Profinet

Posted 13 years ago

How Profinet can provide data for MES and ERP systems

Posted 13 years ago

Baggage handling system uses redundant Profibus DP

Posted 13 years ago

2009 Profibus and Profinet User Conference papers

Posted 14 years ago

Profibus/Profinet TCI specification completed

Posted 14 years ago

Certification of Profinet IO devices is now available

Posted 14 years ago

Free booklet covers Industrial Ethernet and Profinet

Posted 14 years ago

Functional Safety and IT Security for automated manufacturing

Posted 14 years ago

Find out about fieldbus for the UK water industry

Posted 14 years ago

CSi uses Profibus to speed construction of modular palletisers

Posted 14 years ago

More technical articles
3 hours ago
Certified Machinery Safety Expert course on 18th January
In conjunction with TÜV NORD, Pilz Automation UK is hosting its first CMSE Course of 2021. It starts on 18th January and lasts for four days
4 hours ago
Improving communication with (and between) machines
Lenze has published a White Paper discussing PackML, a programming standard defined by OMAC, the Organisation for Machine Automation & Control. Here, Lenze's Marc Vissers provides machine builders with an insight into the paper
5 hours ago
Danfoss buys Artemis Intelligent Power
Danfoss says it will allow them to begin the global commercial rollout of its Digital Displacement® pump technology, a disruptive low-carbon opportunity with applications in the industrial and off-highway markets
1 day ago
Quarter turn fastener that still turns heads
Automotive manufacturers are gradually making the transition from solely manufacturing vehicles to taking on more responsibility for the performance of a vehicle over its life cycle. As a result, OEMs are increasingly looking for ways to lower installation costs, and facilitate quick repeatable access to critical vehicle components in order to enable faster service calls
1 day ago
Wave spring or coil spring?
Simon Ward is Technical Manager at Uckfield-based fastener specialists TFC. Here he offers a machine designers a comparison between wave springs and round wire coil springs 
1 day ago
New course: Safety Design Incorporating EN ISO 13849-1/EN 62061
Pilz Automation UK says that this training course is designed to enable delegates to develop a greater understanding of the processes and standards related to safety control system specification, design and validation
2 days ago
Intelliconnect moves to larger factory as sales grow
Intelliconnect (Europe) Ltd has moved to a larger facility at the Corby Innovation Hub
2 days ago
ABB industrial robots get Wizard programming
ABB is expanding it Wizard easy programming tool to encompass its industrial robot range, saying that it makes robots easier to install, programme and operate without specialised training
2 days ago
New Siemens Sivacon S8 Power Partner appointed
Nottingham-based manufacturer of bespoke LV control systems Blackburn Starling has become a Siemens Sivacon S8 Power Partner
2 days ago
Drive systems enhance rehabilitation technology
maxon Group and Fourier Intelligence have announced a global partnership. maxon's precision drive systems and Fourier' Intelligence rehabilitation robotics will combine in the development of new technologies for patients